Replacement closet flange

ABSTRACT

The present invention provides a replacement closet flange for installing into an end of a drain pipe having an inner surface and a method of assembling a replacement closet flange. In general, the replacement closet flange includes a main body comprising a substantially cylindrical section and a flange section extending radially outward from and approximately perpendicular to an upper end of the cylindrical section, a flexible seal attached to at least a portion of the cylindrical section proximate a lower end thereof and configured, when the replacement closet flange is installed, to sealingly engage with the inner surface of the drain pipe, and at least one retaining clip attached to a location about an outer periphery of the cylindrical section. The retaining clip includes a retaining tab proximate an end thereof configured, when the replacement closet flange is installed, to fixedly engage with an inner surface of the drain pipe.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/238,956, filed on Sep. 21, 2011, which isincorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The present invention relates to devices for use in pipe systems, andmore particularly to a replacement flange for connecting a toilet to adrain pipe or fitting hub.

BACKGROUND

In residential and commercial building construction it is oftennecessary to connect the base of a toilet to a drain pipe in a secureand watertight manner that meets all plumbing codes applicable in thelocal jurisdiction. The most common way of achieving this connection isto utilize a so-called closet flange. A typical closet flange is flatand round and includes a pair of semi-circular diametrically opposedkey-shaped slots, which allow for the insertion of bolts that are usedto tighten the base of the toilet to the flange. Early closet flangeswere made of cast iron and were connected to cast iron drain pipes.Modern closet flanges are typically made of ABS or PVC plastic andinclude a cylindrical body portion that is attached to a drain pipe madeof a similar plastic and an attachment flange portion that extendsradially from the upper end of the main cylindrical body portion and isbolted to the base of the toilet.

In many instances, such as during repair or remodeling activities, itmay become desirable to repair or replace a toilet assembly, which oftenalso requires replacing the associated closet flange. As part of thisprocess, an old or damaged closet flange may be removed from the end ofthe drain pipe and a new replacement closet flange may be installed. Dueto residual components remaining in the end of the drain pipe and/orvarious other factors, however, the replacement closet flange may resistinstallation and/or may tend to back out of the drain pipe or otherwisenot stay installed in the end of the drain pipe. It is desirable,therefore, to provide a replacement closet flange that facilitatesinstallation in the end of a drain pipe.

BRIEF SUMMARY OF VARIOUS EMBODIMENTS

The present invention addresses the above needs and achieves otheradvantages by providing a replacement closet flange for installing intoan end of a drain pipe having an inner surface. In general, thereplacement closet flange includes a main body comprising asubstantially cylindrical section and a flange section extendingradially outward from and approximately perpendicular to an upper end ofthe cylindrical section, a flexible seal attached to at least a portionof the cylindrical section proximate a lower end thereof and configured,when the replacement closet flange is installed, to sealingly engagewith the inner surface of the drain pipe, and at least one retainingclip attached to a location about an outer periphery of the cylindricalsection, wherein the retaining clip includes a retaining tab proximatean end thereof configured, when the replacement closet flange isinstalled, to fixedly engage with an inner surface of the drain pipe,thus locking the replacement closet flange in position.

In some embodiments, the retaining tab may extend outward and upwardfrom the retaining clip. In some embodiments, the retaining tab mayinclude at least one pointed end configured to facilitate engagementwith the inner surface of the drain pipe. In some embodiments, theretaining tab may include two pointed ends configured to facilitateengagement with the inner surface of the drain pipe. In someembodiments, the replacement closet flange may include a plurality ofretaining clips approximately equally spaced about an outer periphery ofthe cylindrical section. In some embodiments, the main body comprisingthe flange section and the cylindrical section may be a single part. Insome embodiments, the flange and cylindrical sections may be constructedof a rigid plastic material, the flexible seal may be constructed of anelastomeric material, and the retaining clip may be constructed of arust inhibitive material. In some embodiments, the rust inhibitivematerial may be stainless steel.

In some embodiments, the flange section may include a groove extendinginto a portion thereof proximate the upper end of the cylindricalsection, and the retaining clip may include an installation tab locatedproximate a second end thereof configured to engage with a surfacewithin the groove, thus securing the retaining clip to the main body. Insome embodiments, the portion of the cylindrical section proximate thelower end thereof may have a decreased outer diameter and may beconfigured to position the flexible seal. In some embodiments, theflexible seal may be attached to the portion of the cylindrical sectionvia a stretch fit. In some embodiments, the flexible seal may furthercomprise at least one outwardly extending tapered ring configured, whenthe replacement closet flange is installed, to sealingly engage with theinner surface of the drain pipe. In some embodiments, the flexible sealmay include a plurality of outwardly extending tapered rings configured,when the replacement closet flange is installed, to sealingly engage theinner surface of the drain pipe.

The present invention also provides a method of assembling a replacementcloset flange. In general, the method includes receiving a main bodycomprising a substantially cylindrical section and a flange sectionextending outward from and approximately perpendicular to an upper endof the cylindrical section, receiving a flexible seal, receiving atleast one retaining clip, wherein the retaining clip includes anoutwardly extending retaining tab located proximate an end thereof,attaching the flexible seal around at least a portion of the cylindricalsection proximate a lower end thereof, and attaching the retaining clipto a location about an outer periphery of the cylindrical section of themain body.

In some embodiments, the flange section may include a groove extendinginto a portion thereof proximate the upper end of the cylindricalsection, and the retaining clip may include an installation tab locatedproximate a second end thereof, and wherein the step of attaching theretaining clip to a location about an outer periphery of the cylindricalsection of the main body may comprise inserting the second end of theretaining clip into the groove such that the installation tab engageswith a surface within the groove, thus securing the retaining clip tothe main body. In some embodiments, the step of receiving at least oneretaining clip may comprise receiving a plurality of retaining clips,each retaining clip including an outwardly extending retaining tablocated proximate an end thereof. In some embodiments, the flangesection may include a groove extending into a portion thereof proximatethe upper end of the cylindrical section, and each of the plurality ofretaining clips may include an installation tab located proximate asecond end thereof, and wherein the step of attaching the retaining clipto a location about an outer periphery of the cylindrical section of themain body may comprise inserting one end of each of the plurality ofretaining clips into the groove of the flange section at approximatelyequal spacing about the outer periphery of the cylindrical section. Insome embodiments, attaching the flexible seal around at least a portionof the cylindrical section proximate a lower end thereof may comprisestretching the flexible seal around the portion of the cylindricalsection proximate the lower end thereof to create a stretch fit.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 is a perspective view of a replacement closet flange inaccordance with one exemplary embodiment of the invention;

FIG. 2 is a top view of a replacement closet flange in accordance withone exemplary embodiment of the present invention;

FIG. 3 is a cross-section view of the replacement closet flange of FIG.2 in accordance with one exemplary embodiment of the present invention;and

FIG. 4 is a partial cross-section view in close-up of a portion of thereplacement closet flange of FIG. 3 in accordance with one exemplaryembodiment of the present invention.

DETAILED DESCRIPTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, the present inventionmay be embodied in many different forms and should not be construed aslimited to the embodiments set forth herein; rather, these embodimentsare provided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

FIG. 1 is a perspective view of a replacement closet flange inaccordance with one exemplary embodiment of the invention. Thereplacement closet flange 100 of the depicted embodiment includes a mainbody 102 that generally comprises a substantially cylindrical section104 and a flange section 106. The flange section 106 extends radiallyoutward from an upper end of the cylindrical section 104 such that theflange section 106 is substantially perpendicular to the upper end ofthe cylindrical section 104. A flexible seal 108 is located proximate alower end of the cylindrical section 104. The replacement closet flange100 of the depicted embodiment also includes a plurality of retainingclips 110. As will be described in more detail below, when thereplacement closet flange 100 is installed into the end of a drain pipe,the flexible seal 108 sealingly engages with an inner surface of thedrain pipe and the retaining clips 110 lock the replacement closetflange 100 in position.

In the depicted embodiment, the main body 102 is a single partcomprising the cylindrical section 104 and the flange section 106,however in other embodiments the cylindrical section 104 and the flangesection 106 could be separate parts that are attached together to createthe main body 102. Although in other embodiments different materials maybe used, in the depicted embodiment the main body 102 is constructed ofa rigid plastic material (such as, but not limited to, polyvinylchloride (PVC) or acrylonitrile butadiene styrene (ABS)), the flexibleseal is constructed of an elastomeric material (such as, but not limitedto, a rubber material), and the retaining clips are constructed of arust inhibitive material (such as, but not limited to, stainless steel).

FIG. 2 is a top view of a replacement closet flange in accordance withone exemplary embodiment of the present invention. In the depictedembodiment, the replacement closet flange 100 includes edge recesses 116and a pair of semi-circular opposed key-shaped slots 112 for receivingbolts that are used to secure the flat underside of the base of a toiletto the flange section 106 of the replacement closet flange 100. In atypical installation, the cylindrical section 104 of the replacementcloset flange 100 extends through a hole in the floor through which thetop end of a drain pipe is accessible such that the flange section 106of the replacement closet flange 100 overlaps the floor. Counter-sunkholes 114 are also formed in the flange section 106 to facilitate otherforms of connection between the replacement closet flange 100 and thefloor.

FIG. 3 is a cross-section view of the replacement closet flange of FIG.2 taken along line A-A, in accordance with one exemplary embodiment ofthe present invention. As shown in the figure, each of the retainingclips 110 includes a retaining tab 118 proximate a lower end thereof. Invarious embodiments, when the replacement closet flange 100 is installedinto the drain pipe the retaining tab 118 is configured to fixedlyengage with the drain pipe inner surface, thus locking the replacementcloset flange 100 in position. In the depicted embodiment, the retainingtab 118 is a portion of the retaining clip 110 that extends upward andoutward from the remaining portion of the retaining clip 110 and thatincludes two pointed ends 120 (see FIG. 1). In such a manner, while theretaining tab 118 is configured to allow insertion of the replacementcloset flange 100 into the end of the drain pipe (i.e, by deflectinginward), the pointed ends 120 of the retaining tab 118 are configured todig into the inner surface of the drain pipe.

The depicted embodiment of the replacement closet flange 100 includesfour retaining clips 110 approximately equally spaced about an outerperiphery of the cylindrical section 104 of the main body 100. It shouldbe noted that in other embodiments, however, the replacement closetflange may include more or less retaining clips (including as few as oneretaining clip) and the retaining clips may or may not be approximatelyequally spaced about the outer periphery of the cylindrical section 104.It should also be noted that although in the depicted embodiment theretaining tab 118 includes two pointed ends 120, in other embodimentsthe retaining tab may include one pointed end or three or more pointedends. In still other embodiments the retaining tab may not include apointed end, but may otherwise be configured to allow insertion of thereplacement closet flange into the end of the drain pipe while stillfixedly engaging with the inner surface of the drain pipe such that wheninstalled, the replacement closet flange is locked in position.

The flexible seal 108 of the depicted embodiment includes four rings 122each configured to contact the inner surface of the drain pipe. In sucha manner, when the replacement closet flange 100 is installed in the endof the drain pipe, the flexible seal 108 is configured to sealinglyengage with the inner surface of the drain pipe. In the depictedembodiment, the edge of each ring 122 of the flexible seal 108 has asubstantially symmetrical v-shaped profile. It should be noted, however,that in other embodiments the flexible seal may have more or less ringsthan shown in the depicted embodiment (including as few as one ring),and the shape(s) of the ring(s) may differ from those shown in thedepicted embodiment. For example, in some embodiments that have aplurality of rings, each ring may have a different shape and/or edgeprofile, and in some embodiments, each ring may have a different outerdiameter.

The flexible seal 108 of the depicted embodiment is attached to thecylindrical section 104 of the main body 102 via a stretch fit. In otherembodiments, however, the flexible seal 108 may be attached in a varietyof other ways, including, but not limited to, welding, gluing, or insertmolding. In the depicted embodiment, the cylindrical section 104 of themain body 102 also includes a portion 124 having a decreased outerdiameter as compared to outer diameter of the remaining portion of thecylindrical section 104. As such, the decreased outer diameter portion124 of the cylindrical section 102 may serve as a locating feature whenpositioning the flexible seal 108 during assembly of the replacementcloset flange 100.

FIG. 4 is a partial cross-section view in close-up of a portion of thereplacement closet flange of FIG. 3 in accordance with one exemplaryembodiment of the present invention. Dashed lines indicate theapproximate location of the floor 126 and an inner surface 128 of thedrain pipe when the replacement closet flange 100 is installed. Althoughin the figure the flexible seal 108 and the retaining tab 118 are shownin an undeflected state, as demonstrated schematically by theirrespective overlapping positions, it is clear that when the replacementcloset flange 100 is installed into the end of a drain pipe, the rings122 of flexible seal 108 deflect and sealingly engage with the innersurface 128 of the drain pipe and the retaining clips 110 deflect andfixedly engage with the inner surface 128 of the drain pipe.

The main body 102 includes a groove 130 extending into a portion of theflange section 106 proximate the upper end of the cylindrical section104. In such a manner, the upper ends of the retaining clips 110 may beinserted into the groove 130. In the depicted embodiment, each retainingclip 110 also includes an installation tab 132 that is configured tofixedly engage with a surface within the groove 130. In such a manner,when the upper end of the retaining clip 110 is inserted into the groove130, the retaining clip 110 is locked in position against thecylindrical section 104 of the main body 102. In the depictedembodiment, the installation tab 132 is a portion of the retaining clip110 that extends downward and outward from the remaining portion of theretaining clip 110 and that includes two pointed ends 134. In such amanner, while the installation tab 132 is configured to allow insertionof the retaining clip 110 into the groove 130 of the main body 102(i.e., by deflecting inward), the pointed ends 134 of the installationtab 132 are configured to dig into a surface of the groove 130.

It should be noted that although in the depicted embodiment theinstallation tab 132 includes two pointed ends 134, in other embodimentsthe installation tab may include one pointed end or three or morepointed ends. In still other embodiments, the installation tab may notinclude a pointed end, but may otherwise be configured to allowinsertion of the retaining clip into the groove while still fixedlyengaging with a surface of the groove such that when installed, theretaining clip is locked in position. It should further be noted thatalthough in the depicted embodiment the retaining clips 110 are attachedto the main body 102 using a groove, in other embodiments individualslots may be provided at each retaining clip position instead of asingle groove. In still other embodiments, the retaining clips may beattached to the main body in a variety of other ways, including, but notlimited to, welding, gluing, or insert molding.

Many modifications and other embodiments of the invention set forthherein will come to mind to one skilled in the art to which thisinvention pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims. Forexample, although the description above describes using the replacementcloset flange with respect to a drain pipe, it is understood that thereplacement closet flange described herein can be used with respect toany similar apparatus, such as, for example, a fitting hub. Althoughspecific terms are employed herein, they are used in a generic anddescriptive sense only and not for purposes of limitation.

That which is claimed:
 1. A replacement closet flange for installinginto an end of a drain pipe having an inner surface, said replacementcloset flange comprising: a main body comprising a substantiallycylindrical section and a flange section extending radially outward fromand approximately perpendicular to an upper end of the cylindricalsection; a flexible seal attached to at least a portion of thecylindrical section proximate a lower end thereof and configured, whenthe replacement closet flange is installed, to sealingly engage with theinner surface of the drain pipe; and at least one retaining clipattached to a location about an outer periphery of the cylindricalsection, wherein the retaining clip includes a retaining tab proximateone end of the retaining clip configured, when the replacement closetflange is installed, to fixedly engage with an inner surface of thedrain pipe, thus locking the replacement closet flange in position, andan installation tab located proximate a second end of the retaining clipconfigured to engage with the main body, thus securing the retainingclip to the main body.
 2. The replacement closet flange of claim 1,wherein the retaining tab extends outward and upward from the retainingclip.
 3. The replacement closet flange of claim 1, wherein the retainingtab includes at least one pointed end configured to facilitateengagement with the inner surface of the drain pipe.
 4. The replacementcloset flange of claim 3, wherein the retaining tab includes two pointedends configured to facilitate engagement with the inner surface of thedrain pipe.
 5. The replacement closet flange of claim 1, wherein thereplacement closet flange includes a plurality of retaining clipsapproximately equally spaced about an outer periphery of the cylindricalsection.
 6. The replacement closet flange of claim 1, wherein the mainbody comprising the flange section and the cylindrical section is asingle part.
 7. The replacement closet flange of claim 1, wherein theflange and cylindrical sections are constructed of a rigid plasticmaterial, the flexible seal is constructed of an elastomeric material,and the retaining clip is constructed of a rust inhibitive material. 8.The replacement closet flange of claim 7, wherein the rust inhibitivematerial is stainless steel.
 9. The replacement closet flange of claim1, wherein the portion of the cylindrical section proximate the lowerend thereof has a decreased outer diameter and is configured to positionthe flexible seal.
 10. The replacement closet flange of claim 1, whereinthe flexible seal is attached to the portion of the cylindrical sectionvia a stretch fit.
 11. The replacement closet flange of claim 1, whereinthe flexible seal further comprises at least one outwardly extendingtapered ring configured, when the replacement closet flange isinstalled, to sealingly engage with the inner surface of the drain pipe.12. The replacement closet flange of claim 1, wherein the flexible sealincludes a plurality of outwardly extending tapered rings configured,when the replacement closet flange is installed, to sealingly engage theinner surface of the drain pipe.
 13. A replacement closet flange forinstalling into an end of a drain pipe having an inner surface, saidreplacement closet flange comprising: a main body comprising asubstantially cylindrical section and a flange section extendingradially outward from and approximately perpendicular to an upper end ofthe cylindrical section; a flexible seal attached to at least a portionof the cylindrical section proximate a lower end thereof and configured,when the replacement closet flange is installed, to sealingly engagewith the inner surface of the drain pipe; and at least one retainingclip attached to a location about an outer periphery of the cylindricalsection, wherein the retaining clip includes a retaining tab proximateone end of the retaining clip configured, when the replacement closetflange is installed, to fixedly engage with an inner surface of thedrain pipe, thus locking the replacement closet flange in position, andan installation tab located proximate a second end of the retaining clipconfigured to engage with the main body, thus securing the retainingclip to the main body, and wherein the flange section includes a slotextending into a portion thereof proximate the upper end of thecylindrical section, and the installation tab is configured to engagewith a surface within the slot.
 14. A method of assembling a replacementcloset flange, said method comprising: receiving a main body comprisinga substantially cylindrical section and a flange section extendingoutward from and approximately perpendicular to an upper end of thecylindrical section; receiving a flexible seal; receiving at least oneretaining clip, wherein the retaining clip includes an outwardlyextending retaining tab located proximate an end thereof, the retainingclip configured, when the replacement closet flange is installed, tofixedly engage with an inner surface of a drain pipe; attaching theflexible seal around at least a portion of the cylindrical sectionproximate a lower end thereof; and attaching the retaining clip to alocation about an outer periphery of the cylindrical section of the mainbody, wherein the retaining clip includes an installation tab locatedproximate a second end thereof, and wherein the step of attaching theretaining clip to a location about an outer periphery of the cylindricalsection of the main body comprises engaging the retaining clip with themain body, thus securing the retaining clip to the main body.
 15. Themethod of claim 14, wherein the step of receiving at least one retainingclip comprises receiving a plurality of retaining clips, each retainingclip including an outwardly extending retaining tab located proximate anend thereof.
 16. The method of claim 15, wherein each of the pluralityof retaining clips includes an installation tab located proximate asecond end thereof, and wherein the step of attaching the retaining clipto a location about an outer periphery of the cylindrical section of themain body comprises engaging the plurality of retaining clips with themain body at approximately equal spacing about the outer periphery ofthe cylindrical section.
 17. The method of claim 14, wherein attachingthe flexible seal around at least a portion of the cylindrical sectionproximate a lower end thereof comprises stretching the flexible sealaround the portion of the cylindrical section proximate the lower endthereof to create a stretch fit.
 18. A method of assembling areplacement closet flange, said method comprising: receiving a main bodycomprising a substantially cylindrical section and a flange sectionextending outward from and approximately perpendicular to an upper endof the cylindrical section; receiving a flexible seal; receiving atleast one retaining clip, wherein the retaining clip includes anoutwardly extending retaining tab located proximate an end thereof, theretaining clip configured, when the replacement closet flange isinstalled, to fixedly engage with an inner surface of a drain pipe;attaching the flexible seal around at least a portion of the cylindricalsection proximate a lower end thereof; and attaching the retaining clipto a location about an outer periphery of the cylindrical section of themain body, wherein the retaining clip includes an installation tablocated proximate a second end thereof, and wherein the step ofattaching the retaining clip to a location about an outer periphery ofthe cylindrical section of the main body comprises engaging theretaining clip with the main body, thus securing the retaining clip tothe main body, and wherein the flange section includes a slot extendinginto a portion thereof proximate the upper end of the cylindricalsection, and the step of attaching the retaining clip to a locationabout a periphery of the cylindrical section of the main body comprisesinserting the second end of the retaining clip into the slot such thatthe installation tab engages with a surface within the slot.